Cheers for the comments guys, long time no update! I have been soo busy with work, life, OU and getting my project car back on the road etc, to update with anything meaningful. Not to say that this is a meaningful post either!
I've not done much with the hardware side, been playing with the Aquaero software getting things right, testing overclocks, temperatures, etc.
The Aquaero can be a bit temperamental to the uninitiated. I had a spate that whenever I adjusted something in Aquasuite, usually the pump curve controller, the Aquaero hardware would crash and reset, or I'd lose mouse control (Aquaero is USB as is my mouse). It was usually due to changing it while it was updating from Aquasuite to the Aquaero - it wouldn't like it and throw it's toys out of the pram. It would bounce back okay, settings saved as if nothing happened. That's all in the past now and it's not crashed/reset since mucking about with it.
The main thing to learn is that when connecting a device to the Aquaero is that the Aquaero should be completely powered off and drained of all power. This is the paramount lesson to take in and heed. It saves a lot of headaches. Connect the device by USB only first, configure it as Aquabus, power down and then connect it via Aquabus. I learned this from Namron and his posts in the SpecialTech forums. He's a member here, and a font of all knowledge Aquacomputer. If you are reading this Namron, I owe you a pint mate!
So I have the D5 pump, the Aqualis reservoir (fill level sensor) and the MPS200 flow sensor all connected to the Aquaero via the Aquabus. How many times do I have to type Aqua.... anyway they are all running in harmony

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At the moment I am testing a control curve for the pump, between 25% and 100% duty depending on the water temp (water OUT). The water temp will never (hopefully) get to the temperature required to run the pump at 100%, which is 40C. Typically the pump runs between 25% (the minimum) and 40% at a water temp of 32C and upwards.
The water temp is obviously controlled by the radiator, who's cooling performance is dictated by the radiators fans. These fans (remember 4x180mm AP181's) are controlled with a separate curve controller. The fans are switched off until the water temp reaches 23C at which point the voltage is set to 25% (about 3.3V) which miraculously is enough to start these fans! From that point the fans voltage (therefore speed) is increased with water temperature (the water IN temp) up to 100% if the water reaches 36C, which it never does

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The third curve controller is for the 3x180mm AP181 fans found at the bottom of the FT02 case. The speed of these 3 fans is linked to the temperature of the motherboards chipset, namely the part that handles the PCIE traffic. This gets damn hot when the 2 670's are running - over 50C. I have noticed that if it gets to about 55C and over, the board can become unstable. To control this temp by controlling the 3 case intake fans, a "software sensor" is used. A software sensor is a feature of the Aquasuite that taps in to a free hardware monitoring program (in my case "Hardware Monitor"

) and allows you to use the reading to control something, it as if connected to the Aquaero. This only works when the program is running, but that's moot. The case intake fans start at 4.5V (must always have some airflow in the case) and stay this until the chipset temp reaches 35C at which point they ramp up with temp until 55C where they run at 12V (100%). Since putting this control in place, the chipset hovers around 53C on load conditions.
That's a lot of words, and I could have just have shown you this:
The little red x's next to the devices simply means they are not connected via USB, they are connected to the Aquaeros's Aquabus.
That's enough Aqua's for one post! I'm still playing with the settings, warm nights are better for this as it tests the limits of the cooling. I'll post sometime soon of the pics A__aero's LCD and the traces I have it configured to display. Handy when the A___suite doesn't show on my other monitor when playing a game.
As always, thanks for reading!